EP3116105B1 - Bobinage en tôle feuilletée - Google Patents

Bobinage en tôle feuilletée Download PDF

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Publication number
EP3116105B1
EP3116105B1 EP16183597.0A EP16183597A EP3116105B1 EP 3116105 B1 EP3116105 B1 EP 3116105B1 EP 16183597 A EP16183597 A EP 16183597A EP 3116105 B1 EP3116105 B1 EP 3116105B1
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EP
European Patent Office
Prior art keywords
conductor
parallel conductors
conductors
sheet
spanwise
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP16183597.0A
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German (de)
English (en)
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EP3116105A1 (fr
Inventor
Mark A. Cleveland
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Boeing Co
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Boeing Co
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Publication of EP3116105A1 publication Critical patent/EP3116105A1/fr
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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/26—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
    • H02K15/0414—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/47—Air-gap windings, i.e. iron-free windings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49009—Dynamoelectric machine

Definitions

  • an ironless core radial flux motor system includes opposing end connectors connected to a central hub at a slip ring.
  • Two conductor sheets span between and are connected to the end connectors.
  • Each conductor sheet includes a number of parallel conductors spaced with apertures between them.
  • the sheets are positioned within the motor system so that the conductors of each conductor sheet fit within the apertures of the other conductor sheet.
  • the conductor sheets are each configured to conduct electrical current in a spanwise direction normal to the radial axis of the circular rotor or stator. The direction of the current alternates from one conductor to the next conductor.
  • motor components may be used below to generically refer to a rotor, a stator, or any combination of rotor and/or stator. It should be appreciated that depending on the particular application, the windings disclosed herein may be utilized to create a rotor or a stator. For example, if manufactured from aluminum, it may be advantageous to utilize the windings described below as a rotor for cooling purposes. However, the windings described herein could also be manufactured from copper or other material, with use in conjunction with augmented cooling techniques such as forced air or liquid cooling.
  • FIGURE 1B shows a cross-sectional view of the rotor disk 102 taken along line A-A in FIGURE 1A .
  • the conductors 108 are created along an annular joggle such that the conductor surface 112 defines a plane that is parallel to, but offset from, the plane containing the outer ring 104 and inner ring 106 of the rotor disk 102.
  • the conductor surface 112 is shown and described as being configured in a plane that is parallel to the plane containing the outer ring 104 and inner ring 106, any plane angle may be used for the conductor surface 112 according to the particular implementation of the rotor disk 102.
  • Aluminum provides a benefit over traditional iron-cored, copper-wrapped windings for several reasons.
  • the weight of an aluminum winding according to the concepts described herein is significantly less than that of a comparable conventional winding. As mentioned above, this weight savings provides a significant benefit to the aircraft industry, as well as uses within other vehicles or any other application in which weight is a design issue.
  • Aluminum is typically purposefully avoided for applications within electric motors. The reason for this is that aluminum has a higher resistance than other commonly used conductive materials, which equates to aluminum heating up more than conventional materials.
  • Aluminum is also a material that is commonly used in the aircraft industry. The manufacturing process utilized to cut, bend, weld, electrically isolate, and otherwise manipulate aluminum is already supported, facilitating the manufacturing of aluminum sheet windings. While the various embodiments described herein are discussed in the context of the use of aluminum on a spinning rotor, it should be understood that copper or other conductive materials may alternatively be used.
  • the laminated sheet winding concepts described herein may be alternatively used on a stator, with force, liquid, or other cooling techniques.
  • the vertically laminated sheets 304 serve as an effective technique for minimizing eddy currents produced by high speed rotation of the of the rotor.
  • the conductors 108 may each be connected to the outer ring 104 and inner ring 106 to create the rotor disk 102. Any resistance welding or other techniques may be used to create the weld 306 that secures the conductors 108 in place.
  • the radial flux winding includes an outer rotor, or motor component, 402A and an inner rotor, or motor component, 402B.
  • the outer rotor 402 and the inner rotor 402B may each be created in a similar manner as the rotor disks 102 described above, utilizing stacked sheets of aluminum or other conductive material.
  • FIGURE 5 shows another embodiment in which the radial flux laminated sheet winding 504 is created using two opposing non-conductive end annular end connectors 506 connected to a central hub.
  • Alternating conductors 508A-508C (collectively 508) of separate conductor sheets bridge the end connectors 506, each conductor 508 extending spanwise across the gap between the end connectors 506 and connected at opposing ends to the end connectors 506.
  • the term conductor sheet in this context refers to all conductors 508 that are electrically connected in series. For example, in this embodiment, there are three conductor sheets corresponding to three phases of power.
  • the first conductor sheet includes all conductors 508A.
  • the second conductor sheet includes conductors 508B.
  • the third conductor sheet includes conductors 508C.
  • the conductors 508 abut one another along a spanwise edge and alternate between sheets.
  • conductor 508A abuts conductor 508C at a front spanwise edge and conductor 508B at a rear spanwise edge.
  • Conductor 508B similarly abuts connector 508A at a front spanwise edge and connector 508C at a rear spanwise edge.
  • the routine 800 continues to operation 804, where the conductors 508/602 are cut or otherwise formed from conductive material like aluminum.
  • the conductors 508 may be formed from laminated stacks of material to create eddy current control slots 512 between sheet laminations in order to minimize eddy currents created by the high rotational velocity of the rotor.
  • the conductors 602 may be cut from a sheet in similar manner as described above with respect to conductors 108.
  • the conductors 508/602 are mounted to the end connectors in a parallel configuration normal to the radial axis of the end connectors 506/606 and abutting one another along the spanwise edges of the conductors.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Windings For Motors And Generators (AREA)
  • Manufacture Of Motors, Generators (AREA)

Claims (6)

  1. Système de moteur à flux radial à noyau sans fer, comprenant :
    une paire de connecteurs d'extrémité annulaires opposés (506, 606) fixés à un moyeu central ;
    une première tôle conductrice (508, 602) comprenant des bords opposés et une première pluralité de conducteurs parallèles s'étendant entre les bords opposés avec une première pluralité d'ouvertures entre conducteurs entre la première pluralité de conducteurs parallèles, la première tôle conductrice formant un composant de moteur circulaire avec la première pluralité de conducteurs parallèles configurés perpendiculairement à un axe radial du composant de moteur circulaire ; et
    une deuxième tôle conductrice (508, 602) comprenant des bords opposés et une deuxième pluralité de conducteurs parallèles s'étendant entre les bords opposés avec une deuxième pluralité d'ouvertures entre conducteurs entre la deuxième pluralité de conducteurs parallèles,
    dans lequel la deuxième tôle conductrice est montée sur la paire de connecteurs d'extrémité annulaires opposés au voisinage de la première tôle conductrice à l'intérieur d'une ouverture entre conducteurs de la première pluralité d'ouvertures entre conducteurs de telle sorte que chaque conducteur de la deuxième pluralité de conducteurs parallèles jouxte un conducteur de la première pluralité de conducteurs parallèles le long d'un bord dans la longueur du conducteur,
    dans lequel la première pluralité de conducteurs parallèles sont configurés pour conduire un courant électrique dans une direction dans la longueur perpendiculairement à l'axe radial du composant de moteur circulaire, en changeant de sens avec chaque conducteur consécutif de la première pluralité de conducteurs parallèles, et
    dans lequel la deuxième pluralité de conducteurs parallèles sont configurés pour conduire un courant électrique dans une direction dans la longueur perpendiculairement à l'axe radial du composant de moteur circulaire, en changeant de sens avec chaque conducteur consécutif de la deuxième pluralité de conducteurs parallèles.
  2. Système de moteur à flux radial à noyau sans fer de la revendication 1, comprenant en outre :
    une troisième tôle conductrice (508, 602) comprenant des bords opposés et une troisième pluralité de conducteurs parallèles s'étendant entre les bords opposés avec une troisième pluralité d'ouvertures entre conducteurs entre la deuxième pluralité de conducteurs parallèles,
    dans lequel la troisième tôle conductrice est montée sur la paire de connecteurs d'extrémité annulaires opposés au voisinage de la deuxième tôle conductrice à l'intérieur d'une ouverture entre conducteurs de la première et la deuxième pluralité d'ouvertures entre conducteurs de telle sorte que chaque conducteur de la troisième pluralité de conducteurs parallèles jouxte un conducteur de la deuxième pluralité de conducteurs parallèles le long d'un bord avant dans la longueur du conducteur et jouxte un conducteur de la première pluralité de conducteurs parallèles le long d'un bord arrière dans la longueur du conducteur.
  3. Système de moteur à flux radial à noyau sans fer de la revendication 1, dans lequel la première tôle conductrice et la deuxième tôle conductrice sont chacune raccordées électriquement au moyeu central par le biais d'une ou plusieurs bagues collectrices opérationnelles pour transférer de l'énergie entre les première et deuxième tôles conductrices et le moyeu central.
  4. Système de moteur à flux radial à noyau sans fer de la revendication 1, dans lequel les première et deuxième tôles conductrices comprennent de l'aluminium ou du cuivre, les première et deuxième tôles conductrices comprenant des tôles anodisées stratifiées configurées de telle sorte que des stratifications de tôles créent une pluralité de fentes de contrôle des courants de Foucault configurées dans la longueur entre les connecteurs d'extrémité annulaires opposés.
  5. Procédé de fabrication d'un bobinage de tôles stratifiées à noyau sans fer, le procédé comprenant :
    le montage d'une paire de connecteurs d'extrémité annulaires opposés sur un moyeu central ;
    le montage d'une première pluralité de conducteurs parallèles sur la paire de connecteurs d'extrémité annulaires opposés de telle sorte que la première pluralité de conducteurs parallèles soient configurés perpendiculairement à un axe radial de la paire de connecteurs d'extrémité annulaires opposés ;
    le montage d'une deuxième pluralité de conducteurs parallèles sur la paire de connecteurs d'extrémité annulaires opposés au voisinage de la première pluralité de conducteurs parallèles de telle sorte que chaque conducteur de la deuxième pluralité de conducteurs parallèles jouxte un conducteur de la première pluralité de conducteurs parallèles le long d'un bord dans la longueur du conducteur ;
    le raccordement électrique de la première pluralité de conducteurs parallèles pour conduire un courant électrique dans une direction dans la longueur perpendiculairement à l'axe radial, en changeant de sens avec chaque conducteur consécutif de la première pluralité de conducteurs parallèles ; et
    le raccordement électrique de la deuxième pluralité de conducteurs parallèles pour conduire un courant électrique dans une direction dans la longueur perpendiculairement à l'axe radial, en changeant de sens avec chaque conducteur consécutif de la deuxième pluralité de conducteurs parallèles.
  6. Procédé de la revendication 5, comprenant en outre :
    le montage d'une troisième pluralité de conducteurs parallèles sur la paire de connecteurs d'extrémité annulaires opposés au voisinage de la deuxième pluralité de conducteurs parallèles de telle sorte que chaque conducteur de la troisième pluralité de conducteurs parallèles jouxte un conducteur de la deuxième pluralité de conducteurs parallèles le long d'un bord avant dans la longueur du conducteur et jouxte un conducteur de la première pluralité de conducteurs parallèles le long d'un bord arrière dans la longueur du conducteur ; et
    le raccordement électrique de la troisième pluralité de conducteurs parallèles pour conduire un courant électrique dans une direction dans la longueur perpendiculairement à l'axe radial, en changeant de sens avec chaque conducteur consécutif de la troisième pluralité de conducteurs parallèles, dans lequel la première pluralité de conducteurs parallèles, la deuxième pluralité de conducteurs parallèles et la troisième pluralité de conducteurs parallèles forment un système d'alimentation triphasé opérationnel pour créer un courant alternatif triphasé lorsqu'on le fait tourner à l'intérieur d'un ou plusieurs champs magnétiques.
EP16183597.0A 2010-10-08 2011-09-08 Bobinage en tôle feuilletée Active EP3116105B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US12/901,007 US8395295B2 (en) 2010-10-08 2010-10-08 Laminated sheet winding
EP11758313.8A EP2625771B1 (fr) 2010-10-08 2011-09-08 Bobinage en tôle feuilletée
PCT/US2011/050865 WO2012047442A2 (fr) 2010-10-08 2011-09-08 Bobinage en tôle feuilletée

Related Parent Applications (2)

Application Number Title Priority Date Filing Date
EP11758313.8A Division-Into EP2625771B1 (fr) 2010-10-08 2011-09-08 Bobinage en tôle feuilletée
EP11758313.8A Division EP2625771B1 (fr) 2010-10-08 2011-09-08 Bobinage en tôle feuilletée

Publications (2)

Publication Number Publication Date
EP3116105A1 EP3116105A1 (fr) 2017-01-11
EP3116105B1 true EP3116105B1 (fr) 2019-04-24

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EP11758313.8A Active EP2625771B1 (fr) 2010-10-08 2011-09-08 Bobinage en tôle feuilletée
EP16183597.0A Active EP3116105B1 (fr) 2010-10-08 2011-09-08 Bobinage en tôle feuilletée

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Application Number Title Priority Date Filing Date
EP11758313.8A Active EP2625771B1 (fr) 2010-10-08 2011-09-08 Bobinage en tôle feuilletée

Country Status (5)

Country Link
US (1) US8395295B2 (fr)
EP (2) EP2625771B1 (fr)
JP (2) JP6043723B2 (fr)
IL (1) IL225388A (fr)
WO (1) WO2012047442A2 (fr)

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JPWO2011102150A1 (ja) * 2010-02-18 2013-06-17 アイシン・エィ・ダブリュ株式会社 回転電機用電機子
US8395295B2 (en) * 2010-10-08 2013-03-12 The Boeing Company Laminated sheet winding
US20140262499A1 (en) * 2013-03-14 2014-09-18 Boulder Wind Power, Inc. Methods and apparatus for optimizing electrically inoperative zones on laminated composite assemblies
US9793775B2 (en) 2013-12-31 2017-10-17 Boulder Wind Power, Inc. Methods and apparatus for reducing machine winding circulating current losses
US10491069B2 (en) 2014-09-16 2019-11-26 Greentech Motors Corporation Electric motor with laminated sheet windings
US11043885B2 (en) * 2016-07-15 2021-06-22 Genesis Robotics And Motion Technologies Canada, Ulc Rotary actuator
CN108242860A (zh) * 2016-12-27 2018-07-03 维尔纳（福建）电机有限公司 一种无铁芯定子及电机
DE102017207659B4 (de) * 2017-05-08 2019-11-14 Audi Ag Elektrische Maschine sowie Verfahren zum Herstellen einer elektrischen Maschine
US11588363B2 (en) * 2020-07-25 2023-02-21 Beta Air, Llc Integrated electric propulsion assembly

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Also Published As

Publication number Publication date
JP6043723B2 (ja) 2016-12-14
JP6159774B2 (ja) 2017-07-05
EP2625771B1 (fr) 2016-11-30
IL225388A0 (en) 2013-06-27
WO2012047442A3 (fr) 2014-02-27
US8395295B2 (en) 2013-03-12
JP2014507102A (ja) 2014-03-20
EP3116105A1 (fr) 2017-01-11
JP2016054637A (ja) 2016-04-14
US20120086296A1 (en) 2012-04-12
IL225388A (en) 2017-05-29
WO2012047442A2 (fr) 2012-04-12
EP2625771A2 (fr) 2013-08-14

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